[sijuko]

Hi Experts,
I am using a 96 model MM540 and its always over heating during the climbs, temp goes beyond 100 quickly and keeps on increasing and if you return back to flat roads or stop and idle the engine it gradually comes back to 80 or less.When engine is hot i am loosing power as well.

Below items are already taken care.
1.Brand new copper radiator and a tight cap
2.Brand new water pump and water hoses
3.Brand new drive belt and it is tight enough
4.Engine is completely overhauled.
5.Using coolant + water

I have been using this vehicle from last 15 years and recently started participating in off-road events and now i am in this situation.

Yet to try out
1.Adding a condenser fan in front of the radiator
2.Upgrading to DI/MDI engine.

MODS - Please approve this thread as i have gone through the other threads and didn't find a solution for this scenario/combination.

[Jaggu]

Originally Posted by sijuko

1.Brand new copper radiator and a tight cap

Have you checked the ratings on the cap, if it matches for XDP engine?

Since you seem to have taken care of most of the usual suspects on cooling side. One if you have the fan shroud around the radiator? that makes a difference and next is like you wanted to try, adding an additional electric fan outside and make sure it is pushing the air inside and not turning other way around.

Other thing that you can check is the fuel pump, how the pump is tuned since the engine is newly done, if it is not set too lean?

How much has the engine run after rebuild?

[sijuko]

Thanks Jaggu,my comments inline

Originally Posted by Jaggu

Have you checked the ratings on the cap, if it matches for XDP engine?

Didn't knew this i will check it and do some research.

Originally Posted by Jaggu

One if you have the fan shroud around the radiator?

Yes, the engine side fan has a shroud.

Originally Posted by Jaggu

Other thing that you can check is the fuel pump, how the pump is tuned since the engine is newly done, if it is not set too lean?

Both pump and engine work was done around same time, need to check with the mech about the tuning settings.

Originally Posted by Jaggu

How much has the engine run after rebuild?

4000 KM

[Jaggu]

Originally Posted by sijuko

Yes, the engine side fan has a shroud.

Check if the shroud is properly sealed at radiator end without any large gaps, some heat resistant sponge type packing can help close the gap if there. Also fan placement is proper. If you have a pic, that will help. Issue with custom built radiators are these finer details, that plays havoc with heating in older Diesel engines.

[GTO]

Common problem with that Mahindra 2.1L. How I solved the overheating issues in my Jeep:

- Good shroud / cowl for the fan.

- Big radiator from Lawrence Radiators. Bought the biggest that would fit.

- Electric fan was lined up in case all that didn't work, but we didn't need it.

[sijuko]

Originally Posted by Jaggu

Check if the shroud is properly sealed at radiator end without any large gaps, some heat resistant sponge type packing can help close the gap if there. Also fan placement is proper. If you have a pic, that will help. Issue with custom built radiators are these finer details, that plays havoc with heating in older Diesel engines.

Very good point, I think the shroud has some gap. Let me check it tomorrow in the daylight. I will also post the picture to show the fan placement.

Originally Posted by GTO

Common problem with that Mahindra 2.1L. How I solved the overheating issues in my Jeep:

- Good shroud / cowl for the fan.

- Big radiator from Lawrence Radiators. Bought the biggest that would fit.

- Electric fan was lined up in case all that didn't work, but we didn't need it.

Mine is also a new copper radiator need to check the size or model. Will you be able to share the measurement if possible? so that i can just validate it with mine as well.

[MB4DI]

Hi,

Just wanted to share one mod done by someone I know, he has used Tata Xenon radiator which has got dual electric fans with sealed shroud along with its degassing tank unit. It has helped him tremendously in keeping the coolant temperature under control even during the inclines with AC ON in summers.


Regards,
MB4DI

[sijuko]

Originally Posted by Jaggu

If you have a pic, that will help

Attaching some of the photos i took just now.

[sijuko]

Also gap between radiator core and fan is 2.4 cm

[Jaggu]

Ok this is an old school built shroud, but I think the outer pieces are missing from it. Look at this post, you should get what I am referring to. https://www.team-bhp.com/forum/4x4-t...ml#post2398648 (AC for MM550 (and Jeeps in general))

Unless there is a decent covering, the fan will not be able to do the required air volume displacement to keep the engine cool.

Originally Posted by sijuko

Also gap between radiator core and fan is 2.4 cm

check above reply.

[sijuko]

Originally Posted by Jaggu

Ok this is an old school built shroud, but I think the outer pieces are missing from it. Look at this post, you should get what I am referring to. https://www.team-bhp.com/forum/4x4-t...ml#post2398648 (AC for MM550 (and Jeeps in general))

Unless there is a decent covering, the fan will not be able to do the required air volume displacement to keep the engine cool.



check above reply.

Thanks .. Let me check from where i can find this shroud.

[Shubhendra]

Originally Posted by Jaggu

Unless there is a decent covering, the fan will not be able to do the required air volume displacement to keep the engine cool.

Originally Posted by sijuko

Thanks .. Let me check from where i can find this shroud.

The shroud is correct and original. You can put some liner as spacer to reduce the gap.
Are you sure your radiator is brand new and temperature reading ? I have owned a dozen of XDPs and if all the parts mentioned by you is actually done then it should not overheat.

[sijuko]

Originally Posted by Shubhendra

The shroud is correct and original. You can put some liner as spacer to reduce the gap.
Are you sure your radiator is brand new and temperature reading ? I have owned a dozen of XDPs and if all the parts mentioned by you is actually done then it should not overheat.

Thanks,Yes thats what I thought too(original shroud)..I have ordered some foam tape to seal the gaps.
Yes Radiator is just 3 months old and i myself bought temperature reading is accurate as well because i see other systems like loosing oil pressure and loosing engine power.

[Ashley Nair]

Please check if the engine thermostat valve is properly opening.

[Emvi]

Originally Posted by sijuko

I am using a 96 model MM540 and its always over heating during the climbs, temp goes beyond 100 quickly and keeps on increasing and if you return back to flat roads or stop and idle the engine it gradually comes back to 80 or less.When engine is hot i am loosing power as well

I suspect it might be a case of cracked/blown cylinder head gasket. I suggest you to get it checked and if it indeed is what I am suspecting, chances are high that the cylinder head might be distorted or damaged as well. We had a couple of Peugeot powered Mahindras before and have experienced similiar issues as the one you are currently dealing with. If for some reason the engine overheats, the aluminium cylinder head (correct me if I am wrong) has the tendency to distort rather easily. Once distorted, the engine overheats quite frequently accompanied by loss of power when heavily loaded or climbing inclines.